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5 | Assembly

M0691622_en | Installation instructions TM 320-550

5.8 Power connection and wiring

DANGER

When working on electrical components:

Risk of electrocution!

When work is carried out on electrical components:

Always have work carried out by a qualified electrician

Observe the applicable standards and regulations

Work must not be carried out on electrical components by unauthorised persons

5.8.1 Potential equalisation

Remove the cover plates on the bracket of the FGR blower fan and connect the
potential equalisation to the heat exchanger

Establish potential equalisation to all boiler components

Fuel outfeeder, ash removal, induced draught fan, FGR blower fan, flue gas pipe,
pipes, control cabinet etc.

IMPORTANT: The potential equalisation must comply with current directives,
regulations and standards.

5.8.2 Laying of cables

Lay the cables from the components through the cable ducts to the control cabinet

NOTICE! Ensure stability of detached control cabinet as well as a dry and stable
ground!

Wire the connections according to the wiring diagram.

Ensure that there is strain relief for all cables in the control cabinet.

Tie any loose hanging cables to the drive motors using cable ties. The cables must not
come into contact with the stoker duct!

CAUTION! Lay the cables from components without risk of stumbling!

NOTICE! To save from damage use cable ducts or conduits for laying!

Summary of Contents for TM 320-550

Page 1: ...ions TM 320 550 Translation of original German version of installation instructions for technicians Read and follow all instructions and safety instructions All errors and omissions excepted M0691622_...

Page 2: ...0 17 4 3 2 TM 500 550 19 4 3 3 Boiler data for planning the flue gas system 21 5 Assembly 22 5 1 Transport 22 5 2 Temporary storage 22 5 3 Positioning 22 5 3 1 Installing the heat exchanger 23 5 3 2 F...

Page 3: ...27 Installing the induced draught fan 72 5 5 28 Installing the combustion air fan 75 5 5 29 Fitting the temperature sensor under the moving grate 75 5 5 30 Assembling the automatic ignition 76 5 5 31...

Page 4: ...stant further development of our products means that there may be minor differences from the pictures and content If you discover any errors please let us know doku froeling com Subject to technical c...

Page 5: ...nd if measures are not observed it will lead to serious injury or death You must follow the instructions WARNING The dangerous situation may occur and if measures are not observed it will lead to seri...

Page 6: ...installation initial startup and servicing must only be carried out by qualified personnel Heating technicians building technicians Electrical installation technicians Froling customer services The as...

Page 7: ...checking central heating systems Part 1 General requirements and one off inspections NORM M 7510 4 Guidelines for checking central heating systems Part 4 Simple check for heating plants for solid fuel...

Page 8: ...IMPORTANT Every heating system must be officially approved The appropriate supervisory authority inspection agency must always be informed when installing or modifying a heating system and authorisati...

Page 9: ...ction must be laid out as per NORM DIN EN 13384 1 or NORM M 7515 DIN 4705 1 The flue gas temperatures for clean systems and additional flue gas values can be found in the table in the technical data L...

Page 10: ...ponent made of flammable material 3 Nonflammable insulating material 4 Radiation shield with rear ventilation Minimum distance from flammable substances as per MFeuV1 Germany 400 mm excluding thermal...

Page 11: ...length about the diameter D of the connection line The measuring port must remain closed whenever the system is in operation The diameter of the measuring probe used by Froling customer service is 14...

Page 12: ...alised filling and make up water with an electrical conductivity of up to 100 S cm is recommended in accordance with EN 14868 Advantages of low salt or fully demineralised water Complies with the appl...

Page 13: ...d pressure maintenance units a variable air cushion in the expansion tank is responsible for volume compensation and pressure maintenance If the pressure is too low the compressor pumps air into the t...

Page 14: ...ume of at least 25 litres per kW rated thermal output 3 8 Return lift If the hot water return temperature is below the minimum return temperature some of the hot water outfeed will be mixed in NOTICE...

Page 15: ...oker including burn back protection system 815 930 H3 Height flue gas pipe connection 2005 2075 H4 Height of return connection 640 710 H5 Height of flow connection 1850 2000 B1 Total width including f...

Page 16: ...mbustion chamber ash container F Heat exchanger ash container G Induced draught unit fan H Flue gas pipe connection without FGR flue gas recirculation 300 mm 350 mm I Heat exchanger drainage 2 IT 2 IT...

Page 17: ...kg 1450 2200 Weight of the fireclay 2150 2700 Weight of the heat exchanger 1600 2220 Total dry weight including attachments 6330 8470 Heat exchanger water capacity l 780 1040 Water pressure drop T 20...

Page 18: ...y at 30 of rated heat output p 82 1 81 8 Auxiliary current consumption at rated heat output elmax kW 0 634 0 879 Auxiliary current consumption at 30 of rated heat output p 0 280 0 355 Auxiliary curren...

Page 19: ...mbustion chamber kg 2200 Weight of the fireclay 2700 Weight of the heat exchanger 2220 Total dry weight including attachments 8470 Heat exchanger water capacity l 1040 Water pressure drop T 20 10 K mb...

Page 20: ...output p 81 5 Auxiliary current consumption at rated heat output elmax kW 1 190 Auxiliary current consumption at 30 of rated heat output p 0 450 Auxiliary current consumption in standby mode PSB 0 02...

Page 21: ...re at outlet of induced draught housing at partial load Pa 2 mbar 0 02 Recommended maximum chimney draught Pa 60 mbar 0 6 Flue gas pipe diameter mm 300 350 Description TM 5001 Flue gas temperature at...

Page 22: ...kaging r Transport components with care to avoid damage r Protect components against damp r Unloading positioning and installation should only be performed by trained professionals Staff must be train...

Page 23: ...the firebricks B 5 3 2 Fitting the underfloor ash removal system optional If an underfloor ash removal system optional is to be installed the adapter should be fitted as follows when the combustion c...

Page 24: ...ent in the process 5 4 2 Operating and maintenance areas of the equipment The system should generally be set up so that it is accessible from all sides to allow quick and easy maintenance Regional reg...

Page 25: ...xchanger is located to the left or right of the combustion chamber as seen from the front operating side Before you start installation check if the heat exchanger is to be installed on the left or the...

Page 26: ...nd fit onto the bolts Prepare the geared motor r Remove the shipping clamp from the geared motor r Fit the vent screw supplied to the highest point Heat exchanger right r Remove the locking screw with...

Page 27: ...ith the groove of the gears r Slide the key into the groove and fit the shaft retainer 5 5 3 Assembling the stoker unit r Remove the pre assembled adjustable foot r Change the adjustable foot to the o...

Page 28: ...Position the boiler in line with the discharge system or according to the diagram and connect to the discharge system 5 5 5 Fitting the burn back slide valve The burn back slide valve can be positione...

Page 29: ...reassemble on the flange on the other side of the combustion chamber using the bolts NOTICE If the heat exchanger is to the left ensure you complete the following steps on the other side The use of a...

Page 30: ...combustion chamber using a pallet truck Ensure that the locating pins are inserted correctly r Reassemble the heat exchanger on the combustion chamber with the bolts you just removed 31 mm 88 mm r Che...

Page 31: ...e tighten all the screws on the combustion chamber cover 5 5 7 Assembling the case cooling duct optional r Remove the blanking plate from the combustion chamber and the front of the heat exchanger r A...

Page 32: ...Assemble the air flap A with the pressure spring B spacer washer C and circlip D to the air damper E and insert into the duct r Insert the cover plate F to the air damper and attach to the duct r Ass...

Page 33: ...d remove the heat exchanger lever from the shaft r Remove the cover plate with the clamping bracket and fit it on the opposite side E r Remove the spacer sleeve A from the shaft r Remove the bearing b...

Page 34: ...ng various fittings r Fit the supply air duct for the combustion air fan on the outside of the combustion chamber Version with heat exchanger on the left remove the blanking plate from the right and r...

Page 35: ...er pivoting mechanism optional r Assemble the pivoting mechanism hinges optional 5 5 10 Removing the different blanking plugs r Remove the thermal discharge valve blanking plug A and seal the immersio...

Page 36: ...g plug for the temperature sensor under the moving grate B and underpressure controller C r Remove the blanking plug for the combustion chamber temperature sensor D and the combustion chamber overpres...

Page 37: ...t exchanger r Fit the cross pieces on the back of the lengthways struts Ensure that the lugs on the cross pieces and lengthways struts on the combustion chamber slot into each other correctly r Fit th...

Page 38: ...5 Assembly 38 M0691622_en Installation instructions TM 320 550 r Fit hexagonal screws to the entire base frame to provide support r Fit the upper frame element in the middle of the combustion chamber...

Page 39: ...eat exchanger are positioned correctly r Fit the flange for the induced draught to the heat exchanger 5 5 13 Fitting thermal insulation to the boiler r Wrap thermal insulation over ash removal flanges...

Page 40: ...r r Cut the perforations out of the heat insulation mat on the side of the heat exchanger and remove the insulating material FGR duct r Attach the heat insulation mat to the back of the combustion cha...

Page 41: ...ace using tension springs r Cut through and remove the rear part of the heat insulation A from the heat insulation mat to be attached to the side of the heat exchanger r Cut out the insulating materia...

Page 42: ...rial FGR duct r Cut around the heat insulation mat perforations in the middle and the bottom on the outside but do not remove the insulating material Secondary and primary air controllers r Position t...

Page 43: ...e outside of the combustion chamber to the upper frame element Partially tighten the screws r Insert the combustion chamber support elements on both sides into the base frame at the front and back r A...

Page 44: ...ut on the combustion chamber on the heat exchanger side to the support elements and upper frame element The lugs must be aligned properly Partially tighten the screws r Fit the cross pieces on the fro...

Page 45: ...Assembly 5 M0691622_en Installation instructions TM 320 550 45 r Insert the heat exchanger support elements into the base frame...

Page 46: ...crews r Fit the support plate to the combustion chamber lengthways strut r Align the frame and tighten all the screws on the frame element 5 5 16 Installing the insulating side panels The procedures f...

Page 47: ...embling side panels TM 400 500 550 Turbomat TM 400 500 550 53 r Cut out and remove half of the thermal insulation for the heat exchanger drive A and the thermal insulation for the WOS bracket B r Cut...

Page 48: ...he front of the boiler r Optional Cut out the pre punched blanking around the combustion chamber ash removal A insulation and cut out and remove the thermal insulation beneath r Cut out and remove the...

Page 49: ...chamber ash removal B r Hang the insulating side panels on the front outside of the combustion chamber r Remove the PVC plug from the immersion sleeve r Insert the flow temperature sensor A and retur...

Page 50: ...y B through the opening in the frame element and push it into the immersion sleeve r Fit the cover plate with STL to the insulating side panel r Run all the cables from the sensors out through the ins...

Page 51: ...lide on duct The angled part must be on the outside of the combustion chamber Turn the plate 180 when installing the heat exchanger on the left r Cut into the insulating material around the upper FGR...

Page 52: ...t flow A insulation r Optional Cut out the pre punched blanking around the slide on duct automatic ignition B insulation r Fit the insulating side panel above the slide on duct r Wrap the heat insulat...

Page 53: ...e r Cut the pre punched blanking around the connection to the slide on duct cooling E and drainage F from the insulation r Hang the insulating side panels on the back of the heat exchanger For the oil...

Page 54: ...easurement E and combustion chamber temperature sensor F from the insulation r Cut into the thermal insulation around the moving grate maintenance opening G and tertiary air controller H but do not re...

Page 55: ...r Hang the insulating side panels at the front of the heat exchanger r Remove the cap and fixing bolt of the high limit thermostat STL A r Push the STL A from the back and through the cover plate r Re...

Page 56: ...ling A into the immersion sleeve on the heat exchanger side and cut out the pre punched blanking B on the cover plate r Fit the upper cover plate to the back of the combustion chamber r Fit the cover...

Page 57: ...he left r Place the thermal insulation around the FGR duct r Cut out the pre punched blanking around the FGR flange insulation Turn the FGR duct insulation 180 when installing the heat exchanger on th...

Page 58: ...slightly to the right B r Fit the lower cover plate to the upper cover plate 5 5 17 Installing the underpressure controller E E E r Assemble the double thread nipple A reduction union B and hose nipp...

Page 59: ...plug A at connection P1 and fit the hose with the hose clamp r Attach the measuring hose with hose clamp to the measuring nipple 5 5 19 Installing the combustion chamber overpressure monitor and temp...

Page 60: ...tors r Check that the air flaps are at the left stop All air flaps should be are closed Where necessary turn the air flaps to the left stop using pliers L r Set the direction of rotation of the servo...

Page 61: ...ng insert E r Slide in the positive locking insert E on the opposite side motor side R and secure with a shaft retainer D r Close the air flaps by turning anti clockwise r Slide the servo motor on the...

Page 62: ...er left The following instructions are for fitting the automatic heat exchanger ash removal screw unit to a boiler with the heat exchanger mounted on the right The instructions also apply to boilers w...

Page 63: ...with the spacer sleeve F r Slide the key G into the groove and fit the shaft retainer H r Insert the flange plate with the ash screw into the heat exchanger on the back of the boiler and fix in place...

Page 64: ...with each other r Wind the roller chain onto the motor and bearing block sprockets Tension the chain and fix in place with a chain lock r Assemble the ash removal unit flange as shown in the figure b...

Page 65: ...m face outwards r Fit the ash removal unit flange insulation First insert the insulation onto the hooks in the insulating side panel and then secure with screws r Fit the cover plate under the ash rem...

Page 66: ...lever on the ash removal unit flange downwards to fix the ash container in place r Push the key plate into the safety switch r Set the safety switch so that the key plate engages correctly r Tighten...

Page 67: ...e ash removal unit flange with seal onto the combustion chamber on the heat exchanger side r Fit the safety switch on the bracket r Fit the bracket to the insulating side panel Do not fully tighten th...

Page 68: ...e coupling cap in a suitable location where you can find it later It will be needed at ash disposal r Position the ash container at the ash removal unit flange r Push the lever on the side of the ash...

Page 69: ...e motor mounting bracket and then fix in place together with geared motor C with the two lower screws r Fix the sensor G for the function monitor to the bracket F r Set the sensor G for the function m...

Page 70: ...ier r Fit the FGR blower fan with the rubber buffers on the bracket and level TIP Use the spacers A provided to align the FGR blower fan r For boilers without electrostatic precipitators Fit flange pi...

Page 71: ...so screw on the earthing wire supplied with the toothed washer as potential equalisation Seal the connection r Wrap heat insulation around the FGR pipe and fix in place using tension springs r Fit the...

Page 72: ...ate piece NOTICE Insulate pipework on site 5 5 27 Installing the induced draught fan r Mount the induced draught fan bracket onto the flange Align correctly using the adjustable feet and fix in place...

Page 73: ...mpensator using bolts and spacer washers Also screw on the earthing wire supplied with the toothed washer as potential equalisation r Fit the T piece between the induced draught fan and the FGR blower...

Page 74: ...secure it in position with the wing screw r Wrap the heat insulation mat around the induced draught fan flange and fix in place using tension springs Run the cable from the broadband probe and flue g...

Page 75: ...nnector support B to the combustion air fan r Slide the cover plate C over the connector support B r Insert the connector support B into the hole in the insulation r Fit the fishplate A onto the suppl...

Page 76: ...x in place using the double screw clip B r Fit the cover D Fitting the automatic ignition to the slide on duct optional r Remove the blanking plug r Insert the igniter tube A r Attach the double nippl...

Page 77: ...bustion chamber door frames Thread the cable through the door frame and insulation r Fit the burning and combustion chamber door key plate Do not fully tighten the screws yet r Close the doors and as...

Page 78: ...ch the spherical handle to the combustion chamber inspection glass r Place the insulating covers on top of the combustion chamber r Close the heat exchanger cover r Lift the four screws on the outside...

Page 79: ...cover plate with the handle onto the blind flange r Lubricate the bolts with copper paste r Fit the intermediate hinges A onto the joints on the boiler using long bolts B r Fit the end hinges C onto...

Page 80: ...flange r Place thermal insulation around the oil burner flange r Fit the cover plate to the oil burner flange r Fit the safety switch onto the bracket and then the bracket onto the insulation under t...

Page 81: ...precipitator system is placed between the boiler and the induced draught The piping must be provided by the customer in compliance with the recommended distances and the installation plan The pipeline...

Page 82: ...iece 1 4 Dirt trap 1 5 Pressure reducing valve 1 6 Backflow preventer to prevent stagnation water from entering the drinking water network 1 7 Free outlet without counter pressure with observable flow...

Page 83: ...to the external air vent system e g quick vent valve 5 7 2 Connecting up the slide on duct cooling 1 Boiler flow 2 Boiler return 3 Slide on duct for the flow 4 Thermometer recommended 5 Drain cock 6...

Page 84: ...ler components Fuel outfeeder ash removal induced draught fan FGR blower fan flue gas pipe pipes control cabinet etc IMPORTANT The potential equalisation must comply with current directives regulation...

Page 85: ...no electric installations are allowed Entire top of boiler heat exchanger and combustion chamber Entire front of boiler Minimum distance of 150 mm to insulation of the FGR duct All areas of the follo...

Page 86: ...black Checking the setting r Close the door If the door can be opened with the usual force correct setting If the door cannot be opened with the usual force or must be forced open unscrew the locking...

Page 87: ...ng the doors The example below shows how to position the combustion chamber door The procedure is the same for checking the seal on the combustion chamber door r Loosen the nut on the locking hook r T...

Page 88: ...e hose diameter in the heating system however not more than DN 50 r Turn on the main switch r Set the boiler controller to the system type r Load the boiler default values NOTICE For the keypad layout...

Page 89: ...tion at least 60 mass portion 3 15 63 mm max length 350 mm previously referred to as coarse wood chips G100 1 partial load conditions only to a limited extent 2 for hydraulic feeders only NOTICE When...

Page 90: ...ent W30 the boiler s rated heat output can only be guaranteed if it is used with a flue gas recirculation system FGR Miscanthus Switchgrass or elephant grass Latin name miscanthus is a C4 plant Standa...

Page 91: ...suring the following prior to initial start up of the system by Froling customer services Electrical installation Installation of water pipes Connect flue gas including all insulation work Work must c...

Page 92: ...result of drying out too rapidly For this reason the following applies the first time you heat up the boiler r Screed dry the boiler in accordance with the following points r Set the boiler to user l...

Page 93: ...ents corrosion when the boiler is out of service If the boiler is to remain out of service during the winter r Have the system completely drained by a qualified technician Protection against frost 7 2...

Page 94: ...94 M0691622_en Installation instructions TM 320 550...

Page 95: ...M0691622_en Installation instructions TM 320 550 95...

Page 96: ...a e 6 85609 Aschheim 49 0 89 927 926 0 info froeling com Froling srl Via J Ressel 2H I 39100 Bolzano BZ 39 0 471 060460 info froeling it Froling SARL 1 rue Kellermann F 67450 Mundolsheim 33 0 388 193...

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